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Compliance Testing for Locomotive LED Headlights and Auxiliary Lights, Phase IV

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Compliance Testing for Locomotive LED Headlights and Auxiliary Lights, Phase IV Compliance Testing for Locomotive LED Headlights and Auxiliary Lights, Phase IV DOT/FRA/ORD-21/16 Final Report | April 2021 i REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503. 1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED April 2021 Technical Report, July 2020 4. TITLE AND SUBTITLE 5. FUNDING NUMBERS Compliance Testing for Locomotive LED Headlights and Auxiliary Lights, Phase IV DTFRXX-XX-F-00XXX 6. AUTHOR(S) Manuel Meza-Arroyo, Ph.D., AHFP, Peggy A. Shibata, P.E., James K. Sprague Ph.D., P.E., Sean Woods 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ENSCO, Inc. Engineering Systems, Inc. ORGANIZATION REPORT 5400 Port Royal Road 1174 Oak Valley Dr. NUMBER Springfield, VA 22151 Ann Arbor, MI 48108 ENSCO SERV-REPT-0002613 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. U.S. Department of Transportation SPONSORING/MONITORING Federal Railroad Administration AGENCY REPORT NUMBER Office of Railroad Policy and Development Office of Research, Development, and Technology DOT/FRA/ORD-21/16 Washington, DC 20590 11. SUPPLEMENTARY NOTES800 COR: Tarek Omar, Ph.D. 12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE This document is available to the public through the FRA website. 13. ABSTRACT (Maximum 200 words) This report describes the work performed during Phase IV compliance testing of light-emitting diode (LED) fixtures used as locomotive headlights and auxiliary lights. The purpose was to study the performance of the lamps under severe cold weather conditions. Researchers sought to determine whether LED lamps could melt a 1/4-inch-thick layer of ice from a lens surface and whether the lamps would accumulate a coating of snow and ice when operated in the presence of very cold, windblown snow. Throughout the testing, halogen lamps, currently standard equipment on freight locomotives, were used as a performance benchmark. 14. SUBJECT TERMS 15. NUMBER OF PAGES Locomotive headlights, auxiliary lights, LED, halogen, Phase IV compliance 94 testing, cold weather performance, environmental testing, Code of Federal 16. PRICE CODE Regulations §229.125 17. SECURITY 18. SECURITY 19. SECURITY 20. LIMITATION OF ABSTRACT CLASSIFICATION CLASSIFICATION CLASSIFICATION OF REPORT OF THIS PAGE OF ABSTRACT Unclassified Unclassified Unclassified i METRIC/ENGLISH CONVERSION FACTORS ENGLISH TO METRIC METRIC TO ENGLISH LENGTH (APPROXIMATE) LENGTH (APPROXIMATE) 1 inch (in) = 2.5 centimeters (cm) 1 millimeter (mm) = 0.04 inch (in) 1 foot (ft) = 30 centimeters (cm) 1 centimeter (cm) = 0.4 inch (in) 1 yard (yd) = 0.9 meter (m) 1 meter (m) = 3.3 feet (ft) 1 mile (mi) = 1.6 kilometers (km) 1 meter (m) = 1.1 yards (yd) 1 kilometer (km) = 0.6 mile (mi) AREA (APPROXIMATE) AREA (APPROXIMATE) 1 square inch (sq in, in2) = 6.5 square centimeters (cm2) 1 square centimeter (cm2) = 0.16 square inch (sq in, in2) 1 square foot (sq ft, ft2) = 0.09 square meter (m2) 1 square meter (m2) = 1.2 square yards (sq yd, yd2) 1 square yard (sq yd, yd2) = 0.8 square meter (m2) 1 square kilometer (km2) = 0.4 square mile (sq mi, mi2) 1 square mile (sq mi, mi2) = 2.6 square kilometers (km2) 10,000 square meters (m2) = 1 hectare (ha) = 2.5 acres 1 acre = 0.4 hectare (he) = 4,000 square meters (m2) MASS - WEIGHT (APPROXIMATE) MASS - WEIGHT (APPROXIMATE) 1 ounce (oz) = 28 grams (gm) 1 gram (gm) = 0.036 ounce (oz) 1 pound (lb) = 0.45 kilogram (kg) 1 kilogram (kg) = 2.2 pounds (lb) 1 short ton = 2,000 pounds (lb) = 0.9 tonne (t) 1 tonne (t) = 1,000 kilograms (kg) = 1.1 short tons VOLUME (APPROXIMATE) VOLUME (APPROXIMATE) 1 teaspoon (tsp) = 5 milliliters (ml) 1 milliliter (ml) = 0.03 fluid ounce (fl oz) 1 tablespoon (tbsp) = 15 milliliters (ml) 1 liter (l) = 2.1 pints (pt) 1 fluid ounce (fl oz) = 30 milliliters (ml) 1 liter (l) = 1.06 quarts (qt) 1 cup (c) = 0.24 liter (l) 1 liter (l) = 0.26 gallon (gal) 1 pint (pt) = 0.47 liter (l) 1 quart (qt) = 0.96 liter (l) 1 gallon (gal) = 3.8 liters (l) 1 cubic foot (cu ft, ft3) = 0.03 cubic meter (m3) 1 cubic meter (m3) = 36 cubic feet (cu ft, ft3) 1 cubic yard (cu yd, yd3) = 0.76 cubic meter (m3) 1 cubic meter (m3) = 1.3 cubic yards (cu yd, yd3) TEMPERATURE (EXACT) TEMPERATURE (EXACT) [(x-32)(5/9)] °F = y °C [(9/5) y + 32] °C = x °F QUICK INCH - CENTIMETER LENGTH CONVERSION 0 1 2 3 4 5 Inches Centimeters 0 1 2 3 4 5 6 987 1110 1312 QUICK FAHRENHEIT - CELSIUS TEMPERATURE CONVERSION °F -40° -22° -4° 14° 32° 50° 68° 86° 104° 122° 140° 158° 176° 194° 212° °C -40° -30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° For more exact and or other conversion factors, see NIST Miscellaneous Publication 286, Units of Weights and Measures. Price $2.50 SD Catalog No. C13 10286 Updated 6/17/98 ii Acknowledgements The authors acknowledge the support and contributions made by the Association of American Railroads Locomotive Committee LED Headlight-Auxiliary Light Standard Technical Advisory Group. The guidance and railway expertise offered by this group of industry professionals was instrumental in the development of a test methodology that accurately simulated severe winter conditions in which light-emitting diode lamps used in a railroad environment must operate. iii Contents Executive Summary ........................................................................................................................ 1 1. Introduction ................................................................................................................. 3 1.1 Background ................................................................................................................. 3 1.2 Objectives .................................................................................................................... 4 1.3 Overall Approach ........................................................................................................ 4 1.4 Scope ........................................................................................................................... 4 1.5 Organization of the Report .......................................................................................... 4 2. Testing Plan and Requirements ................................................................................... 5 2.1 TAG Testing Requirements ......................................................................................... 5 3. Methodology................................................................................................................ 7 3.1 Lamp Samples ............................................................................................................. 7 3.2 Preliminary Testing and Setup .................................................................................... 7 3.3 Testing Facilities ......................................................................................................... 9 3.4 Ice Melt Test .............................................................................................................. 10 3.5 Snow Accumulation Test .......................................................................................... 11 4. Results and Discussion .............................................................................................. 13 4.1 Ice Melt Test Results ................................................................................................. 13 4.2 Snow Accumulation Test Results .............................................................................. 19 4.3 Discussion of Ice Melt and Snow Accumulation Tests ............................................. 28 5. Conclusion ................................................................................................................. 29 6. References ................................................................................................................. 30 Appendix A. Lamp Samples ......................................................................................................... 31 Appendix B. Ice Melt Test – Selected Photographs ..................................................................... 37 Appendix C. Snow Accumulation Test – Selected Photographs .................................................. 41 Appendix D. General Documentation – Selected Photographs .................................................... 52 Appendix E. Power Supply Datasheet .......................................................................................... 58 Appendix F. ACE Laboratory Technical Specifications Sheet .................................................... 64 iv Illustrations Figure 1. Test frames with light fixtures mounted .......................................................................... 7 Figure 2. Thermal image of preliminary temperature testing ......................................................... 8 Figure 3. Metal test frame with housing
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